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[nicktulloh]

I wouldn't have thought this possible but I have managed to strip the female threads for my front axle (left lower fork casting) on my 2018 DSR.

Anyone have any ideas?

[Kappi]

Is there still material left? If so, and the thread is just mangled, perhaps you can re-cut the threads.

[Say10 15FX 16FXS]

If there are no salvageable threads, you can use a Heli coil insert. This should be easy to do since the fender is removed you should be able to turn the lower leg for easier access.

[Biff]

Wow, I think that is an M20 x 1.5mm pitch thread,  that takes some serious torque or abuse to completely strip out.  There is a helicoil kit for it, but it costs $500: https://www.fastenal.com/products/details/11133735

I can think of a couple other hack-like ways to fix it, but they are too sketchy to post on a public forum. That joint is pretty critical, I would really recommend it get repaired properly, or replaced.

[Richard230]

Perhaps a new fork tube might cost less than a Helicoil kit?

[Say10 15FX 16FXS]

https://www.af1racing.com/DS-FORK-41MM-LEFT-ZM22-08061

$450

I would slide the leg out and take it to a good machinist. If they already had the heli coil kit it might be less. Or they may have another solution. Good luck

[TheRan]

$500 is way overpriced, should be closer to $300 for a kit. Most of that cost is in the tool and tap, you could buy a pack of helicoils for under $50 and take it to a machine shop to get it drilled and tapped and they should be able to whip up a tool easily too if they don't already have one (it's just a rod with a slot in the end).

[rayivers]

Is there still material left? If so, and the thread is just mangled, perhaps you can re-cut the threads.

+1.  I recently had a non-MC stainless-on-stainless galling incident where I was sure the threads were toast, but after running a tap through them they're holding fine.

Just fwiw, none of the motorcycles I've owned have used fork axle threads.

[Richard230]

The few times that I have had to deal with stripped threads on an engine the shop mechanic always used a product called "Time Sert" (or something very similar).  I have suspicion that product is much cheaper than a Helicoil and that is why they use it.